Hot-Melt Strip End-Joining Module for Continuous Splicing
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Solution Overview
Problem
Existing splicing technologies for hot-melt articles are inefficient, requiring manual intervention and allowing only single splicing cycles, leading to slow and hazardous operations, especially when replacing unwinding reels.
Innovation Solution
A process and module that automatically move and position sections of hot-melt articles for continuous splicing cycles, using return rollers and cutting-welding means to achieve edge-to-edge contact and transverse cutting-welding, reducing operator intervention and enabling multiple cycles without stopping the unwinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used for splicing operations, then the splicing process can be completed, but the operation speed is slow and operator safety is compromised
Solution Approach 1:
The splicing device performs splicing operations automatically without requiring manual intervention. The system feeds articles, positions them, and executes welding/cutting cycles autonomously, eliminating operator exposure to hazards while maintaining continuous productivity
Solution Approach 2:
Manual mechanical operations are replaced by an automated control system that coordinates feeding, positioning, welding, and cutting mechanisms. The controller automates the entire splicing cycle, replacing manual mechanical intervention with automated mechanical systems
2Productivity
If a single splicing cycle device is used, then the device complexity is low, but the productivity is limited due to required operator intervention for each cycle
Solution Approach 1:
The splicing device is divided into distinct functional modules: article feeding mechanism, positioning system, welding装置, and cutting装置. Each module operates independently but coordinates through the controller, enabling continuous multi-cycle operation while maintaining manageable system complexity
Solution Approach 2:
The splicing device is designed to handle multiple splicing cycles continuously without reconfiguration. The universal design allows the same apparatus to perform repeated welding and cutting operations on different article pairs, eliminating the need for separate single-cycle devices
3Ease of operation
If operator intervention is required for reel replacement and splicing, then flexibility is maintained, but the operation becomes tedious and hazardous in confined spaces
Solution Approach 1:
The article feeding mechanism automatically supplies articles to the splicing position without manual intervention. The system self-regulates the feeding rhythm and positioning, eliminating the need for operators to manually handle articles in confined spaces
Solution Approach 2:
An automated control system acts as an intermediary between the article supply and the splicing operation. The controller coordinates the feeding mechanism, positioning system, and welding/cutting装置, mediating the entire process without requiring direct operator involvement in the hazardous zone
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables fast, efficient, and safe continuous splicing cycles, reducing operator intervention and improving splicing efficiency by allowing automatic handling of reel replacements and minimizing manual handling in confined spaces.
Implementation Method 1
a first work station capable of ultrasonic welding and cutting two thicknesses of articles
Implementation Method 2
a first work station capable of ultrasonic welding and cutting two thicknesses of articles
Implementation Method 3
a second work station capable of ultrasonic lamination
Data Source
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Figure 5~6
AI summary
The method according to the invention for joining ends comprises at least the steps involving: - providing an installation with a second pay-out reel (B2) around which a second item (3) is wound; - automatically moving a taut length of the second item (3) into an end-joining plane (P) situated off the pay-out path of the first item (2); - automatically moving a taut length of the first item (2) into the end-joining plane (P) so as to bring the length of the first item (2) face to face and edge to edge with the length of second item (3); - automatically bringing the two lengths into contact edge to edge and automatically transversally cutting and bonding the two lengths in order to perform the end-joining operation as such.